Optimisation of laser welding for thin-walled Ti6Al4V glider pressure hull
- Authors: Nel, Matthew Ryan
- Date: 2024-04
- Subjects: Laser welding , Welding , Mechanical engineering
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/64739 , vital:73882
- Description: Laser welding is a type of fusion welding process characterised by deep penetration, low heat input and high welding speed. This dissertation investigates the suitability of this process for the fabrication of an underwater glider buoyancy engine from thin Ti6Al4V alloy sheet. Areas of interest include the effect of process parameters on weld microstructure, static properties (microhardness, tensile and bend tests) and dynamic properties (fatigue tests). The effect of welding speed and laser defocusing were evaluated considering experimental matrices consisting of four different travel speeds and three defocus distances. These were narrowed down to three travel speeds and a single defocus distance, resulting in a final test matrix delivering three different heat inputs. Thereafter, the effect of heat input on static and dynamic properties was investigated. Vickers microhardness tests were carried out to predict weld response during tensile testing, with the expectation being that harder welds would offload more strain. This was confirmed using digital image correlation, which allowed for virtual measurement and visualisation of strain offloading. Bend tests were carried out on parent and welded samples to confirm whether Ti6Al4V could be formed to the correct geometry. Forming Ti6Al4V into a U-shape was the first consideration, since dynamic testing required samples of this geometry with longitudinal weld orientation. A two-stage forming methodology was developed from these experiments. Formed samples were subjected to fatigue tests in a custom designed fatigue platform for testing weld orientation as it would appear in the final component. Prediction of the welded buoyancy engine life was the goal behind these tests. Fracture surfaces were analysed to gain understanding of where crack initiation and final fracture occurred. Porosity served as the primary cause for crack initiation in failed samples. Pore distribution was heaviest in low-heat weldments and decreased with increasing heat input, while pore size increased with increasing heat input. This resulted in medium-heat weldments exhibiting superior performance to that of low- and high-heat ones. It was concluded that the laser welding process is able to produce weldments of sufficient integrity in thin Ti6Al4V sheet-formed components intended for use in glider buoyancy engines. , Thesis (MEng) -- Faculty of Engineering, the Built Environment and Technology, School of Engineering, 2024
- Full Text:
- Date Issued: 2024-04
Laser welding of thin-walled stainless steel tubing
- Authors: Mabveka, Greystone Graham
- Date: 2019
- Subjects: Laser welding , Welding Mechanical engineering
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: http://hdl.handle.net/10948/40690 , vital:36223
- Description: Longitudinal butt welds in the motor industry are increasingly being made by laser welding. One of the materials being welded is thin walled type 441 stainless steel tubing. The welding process parameters should however be optimised to give a weld that possesses acceptable properties. In this research, a Yb:YAG laser machine was used to weld a 1.2mm thick tubing. Laser power and welding speed were varied to achieve an optimum weld whose properties compare well with the parent metal. The two parameters were combined such that the heat input was in the range of 7.5 to 25kJ/m. The welds were characterised by the microstructure from the weld, intergranular attack and mechanical properties. It has been shown by microstructure study that grains originated from ‘weld metal/base metal’ interface and elongated towards the weld centreline. A defined line ran through the interface through the thickness of the plate. Smaller grains were noted around the interface in some welds. Susceptibility to intergranular attack tests showed random ditching in the weld metal microstructure which indicated that the weldments produced were acceptable. Mechanical tests of all welds showed a slight increase in micro-hardness in the weld metal. While the base metal had a micro-hardness range of 160 –199HV0.1, it increased to 187 – 242HV0.1 in the fusion zone. An ANOVA regression of tensile test results predicted an expected maximum of 471MPa to occur when a 1000W power is used at a welding speed of 0.06m/s. Fracture morphology of tensile test samples showed that all failures were by overload. This showed that the weld metal still exhibited similar ductility properties with the base metal.
- Full Text:
- Date Issued: 2019